SOFTAIL REAR AXLE COVER KIT
J018192007-09-11
GENERAL
Kit Number
48112-00
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
INSTALLATION
| 1. | 1988-1999 FLSTF Models: Remove rear muffler heat shield, loosen rear exhaust Torca clamp, then remove rear muffler from support following the instructions in the appropriate Service Manual. 2000 and Later Models: Remove exhaust system following the instructions in the appropriate Service Manual. NOTE In some cases, if bike has been previously serviced, the axle may have been removed and re-installed from the left side (with castle nut and cotter pin on the right). If this is the case, the axle must be removed and installed from the the right. If axle appears as original configuration (as in Figure 1 ), it is not necessary to loosen the rear axle nut or remove the cotter pin (or spring clip) from the rear castle nut. | |||||||||||||||||||
| 2. | All Models: See Figure 1. On the left side of the motorcycle, loosen the axle adjuster screw (1) and jamnut (2) just enough to be able to remove the jamnut. | |||||||||||||||||||
| 3. | 1988-1999 FLSTF Models Only: See Figure 2. On the right side (brake caliper side), use a T40 TORX drive to remove the two pin bolts from caliper. Remove caliper by gently rocking caliper back and forth to compress caliper piston, then carefully slide caliper off brake disc. Use cable strap or other suitable means to support caliper. | |||||||||||||||||||
| 4. | All Models: On the right side, loosen the axle adjuster screw and jamnut just enough to be able to remove the jamnut. | |||||||||||||||||||
| 5. | All Models: See Figure 3. On each side, place retainer clip (oriented as shown) and washer from kit over axle adjuster screw and replace jamnut. Turn in axle adjuster screw until it is in its original position against axle spacer, but leave jamnut loose. NOTE The left and right axle cover bases are different. The right axle cover base is designed to accept 3 cover screws; the left axle cover base is designed to accept 2 cover screws. | 
Figure 1. Rear Axle Hardware 
Figure 2. Removing Brake Caliper and Jamnut 
Figure 3. Install Retainer Clip and Washer | ||||||||||||||||||
| 6. | All Models: See Figure 4. Slide axle cover base over the rear of the swingarm. Locate retainer clip as shown and tighten jamnut. Keep pressure on axle cover base with hand while tightening the jamnut to keep the base close to the down tubes. Repeat this Step for the opposite side cover. NOTE If the cover will not fit over the axle adjuster screw, the original screw may be too long. If this is the case, remove the axle cover and replace the original axle adjuster screw with the shorter axle adjuster screw supplied in this kit. Install using identical procedure. It is possible that in some cases on 1987-1992 Softails, the original adjuster screw and the adjuster screw provided in this kit may both be too long. If this is the case, remove the axle cover and obtain a 3/8-16 x 2-1/4 inch Grade 5 hex head capscrew. Install using identical procedure. The bolt must be fully threaded. | 
Figure 4. Install Axle Cover Base and Set Screw | ||||||||||||||||||
| WARNING After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) | ||||||||||||||||||||
| 7. | 1988-1999 FLSTF Models Only: See Figure 2. On the right side (brake caliper side), use a T40 TORX drive to install the two pin bolts from caliper. Install caliper by gently rocking caliper back and forth to compress caliper piston, then carefully slide caliper onto brake disc. Tighten pin bolts to 20–27 N·m (15–20 ft-lbs). NOTE To avoid over-tightening screw in the following step, use on the small hex wrench provided in the kit. | |||||||||||||||||||
| 8. | See Figure 4. Use the hex wrench provided in the kit to install set screw (2) in rear hole of axle cover base until screw contacts the swingarm and holds the base in place. | |||||||||||||||||||
| 9. | Repeat Step 8 for the opposite axle cover base. | |||||||||||||||||||
| 10. | See Figure 5. Install axle cover cap (1 or 2) with flat head screws (5) from the kit. | |||||||||||||||||||
| 11. | Repeat Step 10 for the opposite axle cover cap. |
SERVICE PARTS
Figure 5. Service Parts: Softail Rear Axle Cover Kit
Table 1. Service Parts: Softail Rear Axle Cover Kit
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Cover cap, axle, left | Not Sold Separately |
2 | Cover cap, axle, right | Not Sold Separately |
3 | Cover, base, left | Not Sold Separately |
4 | Cover, base, right | Not Sold Separately |
5 | Screw, flat head (5)* | Not Sold Separately |
6 | Screw, adjuster (2) | 48473-00 |
7 | Washer, 3/8 inch (2) | 34075-89 |
8 | Clip, retainer (2) | 48474-00 |
9 | Set screw, #8-32 (2) | 3206B |
10 | Wrench, hex 5/64 inch (not shown) | Not Sold Separately |
* For replacement screw, use part number 94224-00 with LOCTITE ® 243 Threadlocker and Sealant - Blue applied. | ||